Floor Element Coupling with Bendable Lips for Vertical Locking
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Solution Overview
Problem
Existing floor coverings with conventional tongue and groove connections or mechanical coupling parts face issues with locking strength, particularly in vertical direction, leading to potential separation and gaps under pressure or tension, especially in wood-based substrates.
Innovation Solution
The floor elements feature male and female coupling parts with a bendable lip-shaped portion and a more massive portion, integrated as one piece, allowing vertical and horizontal locking through a downward movement, using synthetic material for enhanced durability and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional tongue and groove connections or mechanical coupling parts are used, then the floor elements can be assembled, but the locking strength in vertical direction is insufficient leading to separation and gaps under pressure
Solution Approach 1:
The coupling part is divided into two functional segments: a bendable lip-shaped portion that provides vertical locking through elastic deformation, and a more massive portion that provides horizontal stability and structural support. This segmentation allows each part to optimize its specific function while working together as an integrated system.
Solution Approach 2:
The patent changes the physical parameters of the coupling part by using different material properties in different sections: the bendable lip-shaped portion uses material with high elasticity and low stiffness to allow deformation, while the more massive portion uses material with high stiffness and strength for structural support. This parameter variation enables the coupling part to provide both vertical locking and horizontal stability.
2Adaptability or versatility
If wood-based substrates are used for floor elements, then the material is natural and aesthetically pleasing, but the substrate is prone to separation and gaps under tension and pressure
Solution Approach 1:
The patent applies different material qualities to different parts of the floor element system: the substrate can be made of various materials including wood-based materials for aesthetic and structural purposes, while the coupling parts are made of synthetic materials with specifically engineered properties (elasticity, stiffness) to provide reliable mechanical connection. This local differentiation of material quality allows the system to maintain both aesthetic appeal and connection reliability.
Solution Approach 2:
The patent employs composite material construction where synthetic coupling parts (made from materials like polypropylene or polyethylene) are integrated with various substrate materials including wood-based substrates. This composite approach combines the aesthetic and structural benefits of natural materials with the mechanical reliability of synthetic polymers, creating a hybrid system that overcomes the limitations of pure wood-based construction.
3Ease of manufacture
If the coupling part is made as one piece with bendable lip-shaped portion and more massive portion, then the manufacturing is simplified, but the manufacturing precision requirements increase
Solution Approach 1:
The patent merges the bendable lip-shaped portion and the more massive portion into a single integrated coupling part that can be manufactured as one piece using injection molding or extrusion processes. This merging eliminates the need for separate manufacturing and assembly steps, simplifying production despite the increased precision requirements for the mold or die design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design provides a stronger, more stable connection with reduced risk of separation, maintaining precision and integrity under normal use and tension loads, suitable for various materials including wood and synthetic composites.
Implementation Method 1
the male coupling part has a downwardly directed recess dividing this coupling part into, on the one hand, an upwardly directed bendable lip-shaped first portion (17) functioning as one of said vertically active locking portions
Implementation Method 2
an upwardly directed bendable lip-shaped first portion (17) functioning as one of said vertically active locking portions
Data Source
AI summary
A floor covering, made of floor elements, which, at least at two opposite sides, includes a male coupling part and a female coupling part, which allow that two of such floor elements to be interconnected by pushing one of these floor elements with the associated male coupling part, by a downward movement, home into the female coupling part of the other floor element. At least one of the coupling parts, either the male coupling part or the female coupling part, is made as least partially in a filled synthetic material composite, such as extruded wood.